BR112019026996B1 - METHOD FOR PROCESSING A CHEMICAL STREAM AND SYSTEM FOR PROCESSING A CHEMICAL STREAM - Google Patents

Abstract

A method for processing a chemical stream includes contacting a feed stream with a catalyst in an upstream reactor section of a reactor having the upstream reactor section and a downstream reactor section, passing an intermediate product stream to the section of the downstream reactor section and introducing a riser quench fluid into the downstream reactor section, upstream reactor section, or transition section and in contact with the intermediate product stream and the catalyst to slow down or stop the reaction. The method includes separating at least a portion of the catalyst from the product stream, passing the product stream to a product processing section, cooling the product stream, and separating a portion of the riser quench fluid from the product stream. The riser quench fluid separated from the product stream can be recycled back to the downstream reactor section, upstream reactor section, or transition section as the riser quench fluid.

Description

Field

[0001] The present disclosure generally relates to chemical processing systems and, more particularly, to recycling processing quench fluid streams in chemical reactor systems.

Technical Fundamentals

[0002] Light olefins can be used as base materials to produce many types of products and materials. For example, ethylene can be used to make polyethylene, ethylene chloride or ethylene oxides. Such products can be used in product packaging, construction, textiles, etc. Thus, there is a demand in the industry for light olefins, such as ethylene, propylene and butene. Light olefins can be produced by different reaction processes depending on the given chemical feed stream, which can be a product stream from a crude oil refining operation. Many light olefins can be produced through catalytic processes, such as catalytic hydrogenation, for example, in which the feed stream is contacted with a fluidized catalyst in a reactor system that facilitates the conversion of the feed stream into light olefins.

SUMMARY

[0003] Reactor systems for converting feed streams into light olefins and other products may include a reactor portion and a catalyst processing portion. The reactor portion of the reactor system may include an upstream reactor section, a downstream reactor section, and a transition section between the upstream reactor section and the downstream reactor section. The feed stream may be contacted with a catalyst at a reaction temperature in the reactor portion of the reactor system to produce an intermediate stream through one or more chemical reactions. Without some additional change to the system, such as reducing the temperature of the catalyst and/or the intermediate product stream, reactants, intermediates, and/or products in the intermediate product stream passing through the reactor section may continue to react to an intermediate product stream. be separated from the downstream catalyst of the downstream reaction section. However, continued reaction of reactants, intermediates and/or products in the downstream reactor section may result in decreased selectivity of the reaction system and/or increased production of unwanted by-products through side reactions or over-reaction of products in the presence of the catalyst. .

[0004] To improve selectivity and/or reduce the production of unwanted byproducts, a riser quench fluid may be introduced into the downstream reactor section, an upper portion of the upstream reactor section, or the transition section to cooling the catalyst and intermediate product stream to a temperature low enough to slow or stop the catalyzed reactions. This can prevent continued reaction of reactants in side reactions and/or overreaction of products in the intermediate product stream, as the intermediate product stream and catalyst continue to pass through the reactor portion of the reactor system.

[0005] The riser quench fluid introduced into the downstream reactor section, the upstream reactor section, or the transition section may subsequently combine with the intermediate product stream passing out of the reactor system. In conventional processes, riser quench fluid can be recovered from the reactor in a recovery process. For example, this recovered riser extinguishing fluid may be condensed, separated and treated before returning to the process or otherwise discarded. This treatment may take the form of vapor separation or other treatment methods to remove organic compounds and/or other contaminants. However, removing standpipe extinguishing fluid from the system may undesirably place additional load on existing facility treatment systems and add capital costs. Furthermore, the riser quench fluid condensed and recovered from the product stream may contain catalyst fines having relatively high catalytic activity compared to other catalyst in the system. These high-activity catalyst fines can be lost from the reactor system through treatment and disposal of the condensed riser quench fluid or by continuous entrainment of the catalyst fines in the product gas stream.

[0006] According to one or more embodiments, the systems and methods disclosed herein may include a product processing section operable to both cool the product stream and remove at least a portion of the riser quench fluid from the riser stream. product. At least a portion of the riser quench fluid removed from the product stream may be passed/recycled back to the downstream reactor section, upstream reactor section and/or transition section as the riser quench fluid and injected into the reactor. Additionally, the system and method may include a flue gas processing section operable to cool flue gases discharged from the catalyst processing portion of the reactor system. At least a portion of a flue gas quenching fluid used to cool the flue gas in the flue gas processing section may also be recycled back to the downstream reactor section, upstream reactor system, or processing section. transition, so that the riser quenching fluid includes the flue gas quenching fluid. Pass the riser quench fluid removed from the product stream, the flue gas quench fluid, or both, back to the reactor (i.e., the upstream reactor section, the downstream reactor section, or the transition) such as riser quench fluid can reduce the amount of process fluids directed to and treated by treatment systems and can allow for the recovery and recycling of high activity catalyst fines back to the reactor system.

[0007] According to one embodiment, a method for processing a chemical stream may include contacting a feed stream with a catalyst in an upstream reactor section of a reactor system. The reactor system may include the upstream reactor section and a downstream reactor section and contact of the feed stream with the catalyst may cause a reaction that forms an intermediate product stream. The method may further include passing at least a portion of the intermediate product stream and catalyst from the upstream reactor section to the downstream reactor section and introducing a riser quench fluid into the downstream reactor section in the downstream reactor section. upstream reactor section or in a transition section between the downstream reactor section and the upstream reactor section and in contact with at least a portion of the intermediate product stream and the catalyst in the downstream reactor section, in the reactor upstream or in the transition section to slow down or stop the reaction of the intermediate product stream with the catalyst to form a product stream. The riser quench fluid may have a temperature lower than an intermediate product stream temperature. The method may include separating at least a portion of the catalyst from the product stream in a catalyst separation section downstream of the downstream reactor section, passing at least a portion of the product stream and the riser quench fluid to a product processing section and cooling at least a portion of the product stream in the product processing section. The method may further include separating at least a portion of the riser quench fluid from the product stream in the product processing section. The riser quench fluid introduced into the downstream reactor section, the upstream reactor section, or the transition section may include at least a portion of the riser quench fluid separate from the product stream.

[0008] According to another embodiment, a method for processing a chemical stream may include contacting a feed stream with a catalyst in an upstream reactor section of a reactor system. The reactor system may include the upstream reactor section and a downstream reactor section and contact of the feed stream with the catalyst may cause a reaction that forms an intermediate product stream. The method may further include passing at least a portion of the intermediate product stream and catalyst from the upstream reactor system to the downstream reactor section and introducing a riser quench fluid into the downstream reactor section in the downstream reactor section. upstream reactor section or in a transition section between the downstream reactor section and the upstream reactor section and in contact with at least a portion of the intermediate product stream and the catalyst in the downstream reactor section, in the reactor upstream or in the transition section to slow down or stop the reaction of the intermediate product stream with the catalyst to form a product stream. The riser quench fluid may have a temperature lower than a temperature of the intermediate product stream in the downstream reactor section, the upstream reactor section, or the transition section. The method may further include separating at least a portion of the catalyst from the product stream in a catalyst separation section downstream of the downstream reactor section, passing at least a portion of the catalyst to a catalyst processing portion of the reactor system. and processing at least a portion of the catalyst in the catalyst processing portion. Catalyst processing can form a flue gas and a processed catalyst. The method may further include passing at least a portion of the processed catalyst from the catalyst processing portion back to the upstream reactor section, passing the flue gas to a flue gas processing section, thermally contacting the flue gas with a flue gas quenching fluid in the flue gas processing section to cool the flue gas in the flue gas processing section and separate catalyst fines from the flue gas and pass at least a portion of the quenching fluid of flue gas to the downstream reactor section, the upstream reactor section, or the transition section. The riser quenching fluid may include at least a portion of the flue gas quenching fluid.

[0009] According to yet another embodiment, a system for processing a chemical stream may include a reactor portion of a reactor system that includes an upstream reactor section, a downstream reactor section, a transition section between the upstream reactor section and the downstream reactor section, a riser quench fluid inlet positioned to introduce a riser quench fluid into the downstream reactor section, the upstream reactor section, or the transitional; and a separation device operable to separate a catalyst from a product stream. The system may further include a catalyst processing portion that includes a combustor configured to receive catalyst from the separation device and a separation section downstream of the combustor and configured to separate the catalyst from a combustion gas. The system may include a product processing section comprising a product stream inlet in fluid communication with the separation device, a quenching fluid inlet operable to introduce a product quenching fluid into the product processing section, a processed product stream outlet operable to pass a processed product stream out of the product processing section and a quenching fluid outlet fluidly coupled to the riser quenching fluid inlet. The product processing section may be operable to reduce a temperature of the product stream, separate at least a portion of the riser quench fluid from the product stream, and pass at least a portion of the riser quench fluid out. of the quench fluid outlet, wherein the riser quench fluid comprises at least a portion of the riser quench fluid separate from the product stream in the product processing section.

[0010] It should be understood that both the previous brief summary and the following detailed description present embodiments of the technology and should provide an overview or context for understanding the nature and character of the technology, as claimed. The accompanying drawings are included to provide a further understanding of the technology and are incorporated into this specification and constitute part thereof. The drawings illustrate various modalities and, together with the description, serve to explain the principles and operations of the technology. Additionally, the drawings and descriptions must be illustrative only and must not limit the scope of the claims in any way.

[0011] Additional features and advantages of the technology disclosed herein will be set forth in the following detailed description and, in part, will be readily apparent to persons skilled in the art from the description or recognized practicing the technology as described herein. including the following detailed description, the claims, as well as the attached drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The following detailed description of specific embodiments of the present disclosure may be better understood when read in combination with the following drawings, in which similar structure is indicated with similar reference numerals and in which:

[0013] FIG. 1 schematically represents a reactor system according to one or more embodiments described herein;

[0014] FIG. 2 schematically represents a quenching tower of the reactor system of FIG. 1 according to one or more embodiments described herein;

[0015] FIG. 3 schematically represents another embodiment of a reactor system in accordance with one or more embodiments described herein;

[0016] FIG. 4 schematically represents a reactor system flowchart in accordance with one or more embodiments described herein;

[0017] FIG. 5 schematically represents another reactor system flowchart in accordance with one or more embodiments described herein;

[0018] FIG. 6 schematically represents a graph of platinum content versus particle size for a hydrogenation catalyst according to one or more embodiments described herein.

[0019] It should be understood that the drawings are schematic in nature and do not include some components of a reactor system normally employed in the art, such as, without limitation, temperature transmitters, pressure transmitters, flow meters, pumps, valves and the like. It is known that these components are within the spirit and scope of the present disclosed embodiments. However, operational components, such as those described in the present disclosure, can be added to the embodiments described in the present disclosure.

[0020] Reference will now be made in detail to various embodiments, some of which are illustrated in the attached drawings. Whenever possible, the same reference numerals will be used throughout the drawings to refer to the same or similar parts.

DETAILED DESCRIPTION

[0021] The reactor systems and methods disclosed herein may include recycling riser quenching fluid recovered from the product stream in a product processing section, a flue gas quenching fluid from a flue gas processing section, combustion, or both, to the downstream reactor section, upstream reactor section, or transition section as the riser quench fluid to reduce the temperature of the intermediate product stream and the catalyst. Recycle the portion of the riser extinguishing fluid separated from the product stream in the product processing section, the flue gas extinguishing fluid in the flue gas processing section, or both, as the riser extinguishing fluid upstream introduced into the downstream reactor section, upstream reactor section, or transition section can reduce the amount of process fluids directed to and treated by the treatment systems and can allow for the recovery and recycling of high-activity catalyst fines back to the reactor system.

[0022] In non-limiting examples, the reactor systems disclosed herein can be used to produce light olefins from hydrocarbon feed streams. Light olefins can be produced from a variety of feed streams using different catalysts and reaction mechanisms. For example, light olefins can be produced at least by dehydrogenation reactions, cracking reactions, dehydration reactions, and methanol-to-olefin reactions. These types of reactions can utilize different feed streams that are subsequently reacted to form the light olefins. Although reactor systems are described herein in the context of hydrocarbon processing to form light olefins, it should be understood that it is contemplated that the reactor systems and methods described herein may be used in other types of reactor systems. As such, the presently described reactor systems and methods should not be limited solely to embodiments of a hydrocarbon conversion system designed to produce light olefins, such as that depicted in FIG. 1

[0023] Reactor systems and methods for processing chemical streams will now be discussed in detail. The chemical stream that is processed can be referred to as a feed stream, which is processed by a reaction to form a product stream. The feed stream may comprise a composition and, depending on the composition of the feed stream, an appropriate catalyst may be used to convert the contents of the feed stream into a product stream that includes light olefins or other chemicals. For example, a feed stream may comprise at least one of propane, butane, ethane or ethylbenzene, and the reaction system may be a dehydrogenation system in which the feed stream may be converted to light olefins by dehydrogenation in the presence of a dehydrogenation catalyst, such as a catalyst comprising platinum, palladium and/or gallium. Other catalysts and reaction mechanisms can be used to form light olefins from a hydrocarbon feed stream.

[0024] Now, with reference to Figure 1, an example reactor system 102 is schematically represented. The reactor system 102 generally comprises multiple system components, such as a reactor portion 200, a catalyst processing portion 300, and a product processing section 500. As used herein in the context of FIG. 1, reactor portion 200 generally refers to the portion of a reactor system 102 in which main process reaction(s) occur. For example, the reactor system 102 may be a dehydrogenation system in which the feed stream 390 is dehydrogenated in the presence of the dehydrogenation catalyst in the reactor portion 200 of the reactor system 102. The reactor portion 200 comprises a reactor 202 that may include a downstream reactor section 230 and an upstream reactor section 250. According to one or more embodiments, as depicted in FIG. 1, the reactor portion 200 may additionally include a catalyst separation section 210 that serves to separate the catalyst from chemicals formed in the reactor 202. Furthermore, as used herein, the catalyst processing portion 300 refers, generally, to that portion of a reactor system 102 in which the catalyst is processed in some manner, such as by combustion. The catalyst processing portion 300 may comprise a combustor 350 and a riser 330 and may optionally comprise a catalyst separation section 310. The catalyst may be regenerated by burning contaminants such as coke and/or heating the catalyst in the catalyst processing portion. 300. A supplemental fuel may be used to heat the catalyst in the catalyst processing portion 300 if coke or other combustible material is not formed in the catalyst or if an amount of coke formed in the catalyst is not sufficient to be burned to heat the catalyst to a desired temperature. In one or more embodiments, the catalyst separation section 210 may be in fluid communication with the combustor 350 (e.g., via standpipe 426) and the catalyst separation section 310 may be in fluid communication with the upstream reactor section 250 (e.g., via standpipe 424 and transport riser 430).

[0025] As described with respect to FIG. 1, the feed stream 390 may enter the transport riser 430 or the upstream reactor section 250 and the product stream 380 may exit the reactor system 102 via the tube 420. According to one or more embodiments, The reactor system 102 may be operated by feeding a chemical feed (e.g., in a feed stream 390) and a fluidized catalyst to the upstream reactor section 250. The chemical feed contacts the catalyst in the reactor section upstream 250 to form an intermediate current. The intermediate stream and catalyst each flow upward to and through the downstream reactor section 230. The intermediate stream and catalyst may continue to react in the downstream reactor section 230 to produce a chemical product. The chemical and catalyst may be passed out of the downstream reactor section 230 to a separation device 220 in the catalyst separation section 210. The catalyst is separated from the chemical in the separation device 220. The chemical is transported out of the catalyst separation section 210 as the product stream 380. The separated catalyst passes from the catalyst separation section 210 to the combustor 350. In the combustor 350, the catalyst can be processed, for example, by combustion. Then, the catalyst may be passed out of the combustor 350 and through the riser 330 to a riser termination separator 378, where the combustion gas and solid components of the riser 330 are at least partially separated. The remaining combustion gases and solids are conveyed to a secondary separation device 320 in the catalyst separation section 310 where the remaining catalyst is separated from the combustion gases 382 produced from catalyst processing (e.g., gases emitted by catalyst combustion spent or supplementary fuel). The separated catalyst is then passed from the catalyst separation section 310 to the upstream reactor section 250, via standpipe 424 and transport riser 430, where it is further utilized in a catalytic reaction. Thus, the catalyst, in operation, may cycle between the reactor portion 200 and the catalyst processing portion 300. In general, the processed chemical streams, including the feed streams 390 and the product streams, may be gases, and the catalyst may be a fluidized particulate solid.

[0026] According to one or more embodiments described herein, the reactor portion 200 may comprise an upstream reactor section 250, a transition section 258, and a downstream reactor section 230, such as a riser. The transition section 258 may connect the upstream reactor section 250 with the downstream reactor section 230. According to one or more embodiments, the upstream reactor section 250 and the downstream reactor section 230 may each have one, a substantially constant cross-sectional area, whereas the transition section 258 may be tapered and does not have a constant cross-sectional area. The upstream reactor section 250 may generally comprise a larger cross-sectional area than the downstream reactor section 230. In some embodiments, such as those in which the upstream reactor section 250 and the downstream reactor section 250 downstream 230 have similar cross-sectional shapes, the transition section 258 can be formed as a trunk. As described herein, unless explicitly stated, “cross-sectional area” refers to the cross-sectional area of a portion of the reactor part in a plane substantially orthogonal to the general flow direction of reactants and/or products. For example, in FIG. 1, the cross-sectional area of the upstream reactor section 250, the transition section 258, and the downstream reactor section 230 are in the direction of a plane defined by the horizontal direction and the direction toward the page (orthogonal to the direction of motion of fluid, i.e. vertically upwards in FIG. 1).

[0027] As depicted in Figure 1, the upstream reactor section 250 may be positioned below the downstream reactor section 230. Such a configuration may be referred to as an upflow configuration in the reactor 202. The reactor 202 may also be a downflow reactor in which the upstream reactor section 250 may be positioned above the downstream reactor section 230. Other reactor configurations are also contemplated for the reactor portion 200 of the reactor system 102.

[0028] The upstream reactor section 250 may be connected to a transport riser 430 which, in operation, may deliver processed catalyst and/or reactant chemicals in a feed stream 390 to the reactor portion 200. The catalyst Processed and/or reactant chemicals may be mixed with a distributor 260 housed in the upstream reactor section 250. Catalyst entering the upstream reactor section 250 via transport riser 430 may pass through standpipe 424 to a transport riser 430, thereby reaching the catalyst processing portion 300. In some embodiments, the catalyst may come directly from the catalyst separation section 210 via standpipe 422 and to a transport riser 430, where it enters in the upstream reactor section 250. The catalyst may also be fed via 422 directly to the upstream reactor section 250. This catalyst may be deactivated slightly, however, in some embodiments, it may still be suitable for reaction in the upstream reactor section 250. amount 250. As used herein, “deactivated” may refer to a catalyst that is contaminated with a substance, such as coke, or is cooler in temperature than desired. Regeneration can move contaminant such as coke, raise the catalyst temperature, or both.

[0029] Still referring to FIG. 1, the reactor portion 200 may comprise a downstream reactor section 230 that acts to transport reactants, products, and/or catalyst from the upstream reactor section 250 to the catalyst separation section 210. In accordance with some embodiments, the downstream reactor section 230 may include an outer riser section 232 and an inner riser section 234. As used herein, an “outer riser section” refers to the portion of the riser that is outside the downstream reactor section 230. catalyst separation section 210, and an “internal riser section” refers to the portion of the riser that is within the catalyst separation section 210. For example, in the embodiment depicted in FIG. 1, the inner riser section 234 of the reactor portion 200 may be positioned within the catalyst separation section 210, whereas the outer riser section 232 is positioned outside the catalyst separation section 210. Additional aspects of the reactor portion 200 of reactor system 102 can be found in co-pending US Provisional Patent Application 62/502,094, filed May 5, 2017, which is incorporated by reference herein in its entirety.

[0030] As discussed previously, the intermediate product stream may continue to react in the presence of the catalyst in the downstream reactor section 230 until the catalyst is separated from the intermediate product stream in the catalyst separation section 210. The continued reaction of the Intermediate product stream may result in overreaction of products formed by the reaction into other chemical byproducts or may result in continued side reactions, which may reduce the selectivity of the reactor system for desired products and/or increase the production of unwanted byproducts.

[0031] With reference to FIG. 1, the downstream reactor section 230 may include a riser quench fluid inlet 384 positioned to introduce a riser quench fluid 386 into the reactor 202 (i.e., upstream reactor section 250, downstream reactor section downstream 130 and transition section 258). The riser quench fluid inlet 384 may be fluidly coupled to one or more cooling nozzles (not shown) to distribute the riser quench fluid 386 throughout the cross-sectional area of the reactor 202. The riser quench fluid 386 riser 386 may be introduced into the reactor 202 and contacted with the intermediate product stream and the catalyst in the reactor 202. The riser quench fluid 386 may have a temperature lower than a temperature of the intermediate product stream and the catalyst in the reactor 202. reactor 202. Contact of riser quench fluid 386 with the intermediate product stream and the catalyst may slow or stop the reaction of the intermediate product stream with the catalyst to form a product stream. The product stream and catalyst may then pass through the remaining portions of the reactor 202 and be separated from the catalyst in the catalyst separation section 210. The product stream may include the product chemicals produced by the reaction, as well as the riser quench fluid 386, which may be vaporized by introducing riser quench fluid 386 into reactor 202. It is understood that product stream 380 may also include unreacted materials from the feed stream, intermediate species formed in the reactor, byproducts formed from side reactions or overconversion of product chemicals, other species or combinations thereof.

[0032] The riser quench fluid inlet 384 may be disposed at any position along the length L of the downstream reactor system 230. For example, in some embodiments, the riser quench fluid inlet 384 may be positioned in the outer riser section 232 of the downstream reactor section 230 to introduce the riser quench fluid 386 into the outer riser section 232. Alternatively, the riser quench fluid inlet 384 may be positioned at any position along the inner riser section 234 from the downstream reactor section 230 to introduce riser quench fluid 386 into the inner riser section 234. In alternative embodiments, the inlet of riser quench fluid 384 may be positioned in an upper portion of the upstream reactor section 250 or in the transition section 258 between the upstream reactor section 250 and the downstream reactor section 230. In some embodiments, the reactor 202 may include more than one inlet of riser quench fluid 384, and each of the riser quench fluid inlets 384 may be positioned in one of the downstream reactor sections 130, in the upper portion of the upstream reactor section 250, or in the transition section 258.

[0033] Thus, riser quench fluid 386 can be introduced into the intermediate product stream and catalyst at any point between the upper portion of the upstream reactor section 250 and the end of the downstream reactor section 230 prior to catalyst separation section 210. The positioning of the riser quench fluid inlet 384 can influence the progress of the reaction in the reactor 202 and thus can influence the conversion of feed materials into products. The riser extinguishing fluid 386 may be a liquid or a gas. For example, the product quenching fluid 386 may include steam, liquid water, liquid hydrocarbon (e.g., a quenching oil, fuel oil, or other hydrocarbon), or combinations thereof. The liquid hydrocarbon may include hydrocarbons having greater than or equal to 6 carbon atoms, such as from 6 carbon atoms to 25 carbon atoms or from 6 carbon atoms to 20 carbon atoms. In some embodiments, the riser quench fluid 386 may include water. Alternatively, in other embodiments, the riser quench fluid 386 may include liquid hydrocarbon, such as quench oil or fuel oil, for example. In still other embodiments, the riser quench fluid 386 may include one or more of benzene, toluene, pyrolysis gas, or combinations thereof. In some embodiments, the riser quench fluid 386 may also include particulate solids, such as catalyst particles, for example. The presence of catalyst particles in riser quench fluid 386 will be discussed in subsequent sections of this disclosure.

[0034] The temperature of the riser quench fluid 386 may be lower than the temperature of the intermediate stream and catalyst in the reactor 202 (i.e., the upstream reactor section 250, downstream reactor section 230, and transition section 258) greater than or equal to 100°C, greater than or equal to 200°C, greater than or equal to 300°C, greater than or equal to 400°C or greater than or equal to 550°C.

[0035] The introduction of riser quench fluid 386 into reactor 202 may decrease the temperature of the intermediate product stream and catalyst in reactor 202. The decrease in temperature of the intermediate product stream and catalyst in reactor 202 caused by the introduction of riser quench fluid 386 may be sufficient to slow or stop the reactions of the intermediate product stream. For example, in some embodiments, riser quench fluid 386 may reduce the temperature of the intermediate product stream and catalyst by greater than or equal to 5°C, greater than or equal to 7°C, greater than or equal to at least 9°C, greater than or equal to 11°C, greater than or equal to 13°C, greater than or equal to 15°C or greater than or equal to 20°C. Introduction of riser quench fluid 386 into reactor 202 can result in high selectivity of the reaction in favor of selected products and can reduce the formation of unwanted byproducts. Additional examples of introducing a riser quench fluid 386 into a reactor system are disclosed in co-pending US Patent Application 15/034,637, which is incorporated by reference herein in its entirety.

[0036] With reference to FIG. 1, in operation, the introduction of riser quench fluid 386 into reactor 202 can stop or slow down the reaction of the intermediate product stream to form the product stream. The product stream and catalyst may move upward through the remaining portion of the reactor 202 (i.e., the portion downstream of the riser quench fluid inlet 384) and to the separation device 220. The vapors separated from the stream of product 380 may be removed from the reactor system 102 via a tube 420 into a gas outlet port 216 of the catalyst separation section 210. According to one or more embodiments, the separation device 220 may be a separation system cyclonic, which may include two or more stages of cyclonic separation. In embodiments in which the separation device 220 comprises more than one cyclonic separation stage, the first separation device into which the fluidized stream enters is called a primary cyclonic separation device. The fluidized effluent from the primary cyclonic separation device may enter a secondary cyclonic separation device for further separation. Primary cyclonic separation devices may include, for example, primary cyclones and systems commercially available under the names VSS (commercially available from UOP), LD2 (commercially available from Stone and Webster) and RS2 (commercially available from Stone and Webster). Primary cyclones are described, for example, in US Patents 4,579,716; 5,190,650 and 5,275,641, which are each incorporated by reference in their entirety in this document.

[0037] According to some embodiments, after separation of the vapors in the separation device 220, the catalyst may generally move through the separator 224 to the catalyst outlet port 222, where the catalyst is transferred out. from the reactor portion 200 via standpipe 426 and to the catalyst processing portion 300. Optionally, the catalyst may also be transferred directly back to the upstream reactor section 250 via standpipe 422. Alternatively , the catalyst may be premixed with the processed catalyst in the transport riser 430.

[0038] As described in detail according to the embodiment of FIG. 1, in accordance with one or more embodiments, the catalyst may be processed by one or more of the steps of passing the catalyst from reactor 202 to combustor 350, burning a supplemental fuel source or coke deposited on the deactivated catalyst in combustor 350, and passing the heated catalyst from combustor 350 to reactor 202.

[0039] Now referring to the catalyst processing portion 300, as depicted in Figure 1, the combustor 350 of the catalyst processing portion 300 may include one or more lower reactor portion inlet ports 352 and may be in communication with fluid with the riser 330. The combustor 350 may be in fluid communication with the catalyst separation section 210 via the standpipe 426 which may feed spent catalyst from the reactor portion 200 to the catalyst processing portion 300 for regeneration. . The combustor 350 may include an additional reactor section inlet port 352 where the air inlet 428 connects to the combustor 350. The combustor 350 may also include a supplemental fuel inlet 354 for introducing supplemental fuel into the combustor 350. Air 428 can supply reactive gases that can react with the spent catalyst or a supplemental fuel from the supplemental fuel inlet 354 to at least partially regenerate the catalyst. Additional details of the catalyst processing portion can also be found in US Provisional Patent Application Serial No. 62/502,094 previously incorporated by reference.

[0040] With reference to FIG. 1, product stream 380 may be passed from the catalyst separation section 210 of the reactor portion 200 to a product processing section 500 positioned downstream of the catalyst separation section 210. The product stream 380 may optionally be feed stream preheater 392 disposed downstream of the catalyst separation section 210 of the reactor portion 200 and upstream of the product processing section 500. The feed stream preheater 392 may be a heat exchanger operable to heat the feed stream 390 by transferring heat from the product stream 380 to the feed stream 390. Thus, the feed stream preheater 392 can reduce the temperature of the product stream 380 leaving of the feed stream preheater 392 compared to the product stream 380 upstream of the feed stream preheater 392.

[0041] Positioned downstream of the feed stream preheater 392, the product processing section 500 may be operable to further reduce the temperature of the product stream 380. The product processing section 500 may also be operable to remove at least a portion of the riser quench fluid 386 from the product stream 380. Additionally, the product processing section 500 may be operable to remove catalyst fines and other particulate solids from the product stream 380 that have not been separated from the product stream 380 in the catalyst separation section 210. A product quench fluid 510 may be introduced into the product processing section 500 to provide cooling to the product stream 380, remove at least a portion of the riser quench fluid from product stream 380 and/or remove entrained particulate solids (e.g., catalyst fines) from product stream 380.

[0042] Product extinguishing fluid 510 may include steam, liquid water, liquid hydrocarbon (e.g., a extinguishing oil, fuel oil, or other hydrocarbon) or combinations thereof. The liquid hydrocarbon may include hydrocarbons having greater than or equal to 6 carbon atoms, such as from 6 carbon atoms to 25 carbon atoms or from 6 carbon atoms to 20 carbon atoms. In some embodiments, the product extinguishing fluid 510 may include water. Alternatively, in other embodiments, the product extinguishing fluid 510 may include liquid hydrocarbon, such as extinguishing oil or fuel oil, for example. In still other embodiments, the product quench fluid 510 may include one or more of benzene, toluene, pyrolysis gas, or combinations thereof. In some embodiments, the product quench fluid 510 may be the same as the riser quench fluid 386.

[0043] With reference to FIG. 1, stream 514 may be passed out of the product processing section 500 and passed back to the riser quench fluid inlet 384, so that the riser quench fluid 386 is introduced into the reactor 202 (i.e. that is, the downstream reactor section 230, the upstream reactor section 250, or the transition section 258) includes at least a portion of the stream 514. The stream 514 may be a liquid and may include the quench fluid portion. riser 386 recovered from product stream 380. Additionally, stream 514 may include particulate solids, such as catalyst fines, for example, recovered from product stream 380. In some embodiments, stream 514 may also include at least one portion of the product quench fluid 510 introduced into the product processing section 500. As previously described, the riser quench fluid 386 introduced into the downstream reactor section 230 or other part of the reactor 202 may vaporize when contacted with the current of intermediate product and the catalyst in the reactor 202. The vaporized riser quench fluid 386 may pass through the catalyst separation section 210 with the product stream 380. In the product processing section 500, at least a portion of the fluid vaporized riser extinguisher 386 may be condensed and separated from the product stream 380 in the product processing section 500 and may be passed out of the product processing section 500 into the stream 514.

[0044] Passing stream 514 from product processing section 500 back to reactor 202 as riser quench fluid 386 can reduce the amount of stream 514 that, in some embodiments, must be treated prior to reuse or of discarding stream 514. Passing stream 514 back to reactor 202 as riser quench fluid 386 can also improve conversion and selectivity of reactor system 102 by returning catalyst fines to reactor system 102.

[0045] Still referring to FIG. 1, the product processing section 500 may include a product stream inlet 520 in fluid communication with the gas outlet port 216 of the catalyst separation section 210. The product inlet stream 520 may be in fluid communication. fluid with the separation device 220 through the gas outlet port 216. In some embodiments, the optional feed stream preheater 392 may be disposed between the catalyst separation section 210 and the product processing section 500, such that fluid communication between the gas outlet orifice 216 and the product stream inlet 520 of the product processing section 500 may include fluid communication through the feed stream preheater 392. The processing section product stream outlet 500 may also include a processed product stream outlet 522 and a quench fluid outlet 524. The processed product stream outlet 522 may be operable to pass a processed product stream 512 out of the product processing section. 500. In some embodiments, the processed product stream outlet 522 may be fluidly coupled to downstream processing systems for further processing of the processed product stream 512. The quenching fluid outlet 524 may be fluidically coupled to the quenching fluid inlet. riser quench 384 of passing stream 514 back to the reactor system 202 as at least a portion of the riser quench fluid 386. For example, the quench fluid inlet 384 may be positioned in the downstream reactor section 230, in the upper portion of the upstream reactor section 250 or in the transition section 258 between the upstream reactor section 250 and the downstream reactor section 230, so that current 514 can be passed back to the downstream reactor section 230. downstream reactor section 230, upstream reactor section 250, or transition section 258, respectively, as a portion of the riser quench fluid 386. The product processing section 500 may also include a quench fluid inlet 526 operable to introduce product extinguishing fluid 510 into product processing section 500.

[0046] As previously discussed, the product processing section 500 may be operable to reduce a temperature of the product stream 380. A temperature of the processed product stream 512 passed out of the product processing section 500 may be lower than the temperature of the product stream 380 introduced into the product processing section 500. For example, in some embodiments, the difference between the temperature of the product stream 380 introduced into the product processing section 500 and the temperature of the processed product stream 512 passed out of the product processing section can be from 50°C to 500°C, from 50°C to 400°C, from 50°C to 300°C, from 50°C to 200°C, from 100°C to 500°C, from 100°C to 400°C, from 100°C to 300°C, or from 100°C to 200°C.

[0047] The product processing section 500 may be operable to separate at least a portion of the riser quench fluid 386 from the product stream 380. Thus, the weight percentage of riser quench fluid 386 in the product stream 386 product 380 introduced into the product processing section 500 through the product stream inlet 520 may be greater than the weight percentage of riser quench fluid 386 remaining in the processed product stream 512 passed out of the product processing section. product through the processed product stream outlet 522. For example, in some embodiments, the product stream 380 introduced into the product processing section 500 may include greater than or equal to 5% by weight of riser quench fluid 386 with based on the total weight of the product stream 380. After processing the product stream 380 in the product processing section 500, the processed product stream 512 is passed out of the product processing section 500 through the processed product stream outlet 522 may comprise less than 5% by weight of riser quench fluid 386. The product processing section 500 may further be operable to pass at least a portion of the riser quench fluid 386 separate from the product stream 380 to the outside. from the extinguishing fluid outlet 524 as stream 514.

[0048] As discussed previously, the product processing section 500 may be operable to remove particulate solids, including catalyst fines, from the product stream 380. In some embodiments, the processed product stream 512 may be substantially free of particulate solids, such as catalyst fines. As used herein, “substantially free” of a constituent refers to a composition, stream, reaction zone, vessel, reactor, catalyst, or other structure having less than 0.1% by weight of the constituent based on the flow rate of mass of the composition, stream, zone, reactor, catalyst or other structure. For example, the processed product stream 512 that is substantially free of particulate solids may have less than 0.1% by weight of particulate solids based on the total mass flow rate of the processed product stream 512.

[0049] With reference to FIG. 1, stream 514 may be passed from product processing section 500 to riser quench fluid inlet 384 as riser quench fluid 386 and introduced into reactor 202 to cool the intermediate product stream and catalyst in reactor 202. Passing stream 514 to riser quench fluid inlet 384 to introduce stream 514 into reactor 202 as riser quench fluid 386 can reduce the amount of fluids transported to processing systems and/or or downstream treatment, such as water treatment systems in the case of water as the extinguishing fluid or downstream chemical processing systems in the case of hydrocarbon-based extinguishing fluids. Additionally, catalyst fines transferred from product stream 380 to stream 514 in product processing section 500 may be reintroduced into reactor system 102 by passing stream 514 to reactor 202 as riser quench fluid 386.

[0050] It has been discovered that catalyst fines having particle sizes smaller than the average particle size of the catalyst in reaction system 102 can contain a greater amount of a catalytically active material (e.g., platinum, palladium, gallium, etc.) per weight of catalyst than the larger particle size catalyst. With reference to FIG. 6, the relative amount of platinum in a hydrogenation catalyst is shown as a function of catalyst particle size for a used catalyst 640 and a new catalyst 642. As illustrated in FIG. 6, for the used catalyst 640, the relative amount of platinum may be greater for the smaller sized catalyst particles and may decrease with increasing average particle size of the catalyst. Trend line 644 further graphically illustrates the decreasing relative amount of platinum with increasing average particle size for the catalyst used. For new catalyst 642, the relative amount of platinum in the catalyst is generally constant with respect to particle size. It has been demonstrated that high relative amount of platinum in spent catalyst 640 having smaller average particle size results in improved conversion of feed stream 153 compared to spent catalyst 640 having larger average particle size.

[0051] The catalyst particles recovered from the product stream 380 in the product processing section 500 may be catalyst fines having a smaller average particle size compared to the average particle size of the catalyst in the reactor system 102 and therefore , they can be expected to have a greater amount of catalytically active material (e.g. platinum, palladium, gallium, etc.) compared to the average catalyst particles in the reaction system. The catalyst particles recovered from the product stream 380 may be passed back to the reactor system 102 to enhance the reaction of the feed stream 153 with the catalyst to produce the product stream 155. In particular, the return of the catalyst particles recovered from the product processing section 500 to the reaction system 102 may improve the conversion and/or selectivity of the reaction system 102.

[0052] Returning to FIG. 1, in some embodiments, the reactor system 102 may include a product side solids concentrator 504 disposed downstream of the product processing section 500. Stream 514 may be passed from the product processing section 500 to a product processing concentrator. product side solids 504. The product side solids concentrator 504 can separate catalyst particles, such as catalyst fines, from the stream 514 downstream of the product processing section 500 to produce catalyst fines 516 and stream 518. Stream 518 may include a portion of riser quench fluid separate from product stream 380, as well as a portion of product quench fluid introduced into product processing section 500. Stream 518 may be substantially free of chemical particles. catalyst upon passage out of product-side solids concentrator 504. For example, stream 518 may have less than 0.1% by weight of catalyst particles based on the total weight of stream 518. product 504 may include at least one of a liquid candle filter, a bag filter, a filter press, another solids concentrator, or combinations thereof. In some embodiments, the product side solids concentrator 504 may include at least one liquid candle filter.

[0053] Stream 518 may be passed from the product side solids concentrator 504 to the riser quench fluid inlet 384 as a portion of the riser quench fluid 386 to quench the intermediate product stream and catalyst in the reactor 202 (i.e., the downstream reactor section 230, upstream reactor section 250 and/or transition section 258). The catalyst fines 516 may be passed from the product side solids concentrator 504 back to the reactor system 102. For example, the catalyst fines 516 may be passed to the catalyst processing portion 300 or to the reactor section upstream 250 of reactor system 102. In some embodiments, catalyst fines 516 may be passed to combustor 350 or section 312 of catalyst processing portion 300, where catalyst fines 516 may be processed in the processing portion of catalyst 300 before being passed back to the upstream reactor section 250. The catalyst fines 516 may include catalyst fines having a smaller average particle size relative to the average particle size of the catalyst in the reactor system 102. As previously discussed, recovery of catalyst fines 516 from stream 514 and passage of catalyst fines 516 back to reactor system 102 can improve conversion and selectivity of reactor system 102 due to additional catalyst loading into the fines. of catalyst 516.

[0054] Referring now to FIG. 2, in some embodiments, product processing section 500 may include a quench tower system 502. Referring to FIG. 2, the quench tower system 502 may include a quench tower 528 having a product inlet 580, a gas outlet 582, a liquid outlet 584, a quench fluid recycle outlet 586, and a quench fluid recycle inlet. extinguishing fluid 588. The extinguishing tower 528 may also include outlet 590 positioned in a lower portion 690 of the extinguishing tower 502. The product inlet 580 may be positioned in the lower portion 690 of the extinguishing tower 502, so that gaseous portions of the product stream 380 may enter the lower portion 690 of the quench tower 528 and flow upward through the quench tower 528 to the gas outlet 582 disposed at a top of the quench tower 528. The quench fluid recycle inlet 588 may be positioned in an upper portion 692 of the quench tower 528, so that the product quench fluid 510 introduced into the quench tower 528 flows generally downwardly through the quench tower 528. The liquid outlet 584 may be positioned at the bottom of quench tower 528. In this configuration, the flow of product stream 380 upward through quench tower 528 may be countercurrent to the flow of product quench fluid 510 downward through quench tower 528. In some embodiments , the liquid outlet 584 may be the quenching fluid outlet 524 of the product processing section 500.

[0055] The extinguishing tower 528 may further include a plurality of nozzles 530 fluidly coupled to the extinguishing fluid recycle inlet 588. A conduit may fluidly couple the nozzles 530 to the extinguishing fluid recycle inlet 588. The nozzles 530 may be oriented in the quench tower 528 to distribute the product quench fluid 510 downward and across at least a portion of the cross-sectional area of the quench tower 528. In some embodiments, the nozzles 530 may be positioned to distribute the fluid extinguishing fluid 510 across the entire cross-sectional area of the extinguishing tower 528. Nozzles 530 may be positioned in the upper portion 692 of the extinguishing tower 528 to maximize the volume of the extinguishing tower 528 to contact the extinguishing fluid. product 510 with product chain 380.

[0056] In some embodiments, the quench tower 528 may include a demister 532 positioned downstream of the nozzles 530. When referring to the quench tower 528, the term “downstream” is relative to the direction of flow of the product stream 380 through container 528. In the embodiment shown in FIG. 2, the flow of product stream 380 through the quench tower 528 is upward and the positioning of the demister 532 downstream of the nozzles 530 places the demister 532 above the nozzles 530, between the nozzles 530 and the gas outlet 582. demister 532 can capture droplets of product quenching fluid 510 entrained in product stream 380 through contact between product stream 380 and product quenching fluid 510. Droplets of product quenching fluid 510 captured by demister 532 can include solid catalyst particles. Droplets of product quench fluid 510 captured by demister 532 may flow by gravity from demister 532 downward through quench tower 528 to combine with stream 514 in the lower portion 690 of quench tower 528.

[0057] With reference to FIG. 2, in some embodiments, the quench tower 528 may include a chimney tray 536 disposed in the lower portion 690 of the quench tower 528 between the product inlet 580 and the nozzles 530. The chimney tray 536 may be operable to accumulate a volume of extinguishing fluid flowing downward through the extinguishing tower 528. The extinguishing fluid accumulated in the chimney tray 536 may include the product extinguishing liquid 510 introduced into the extinguishing tower 528 at the extinguishing fluid recycle inlet 588 and /or the quenching fluid 386 separated from the product stream 380 in the product processing section 500. The quenching fluids accumulated in the chimney tray 536 may also include catalyst particles, such as catalyst fines or other particulate solids. Extinguishing fluid accumulated in excess of the fixed volume of the chimney tray 536 may overflow through the chimneys to the bottom of the extinguishing tower 528.

[0058] As shown in FIG. 2, the quench tower 528 may optionally include a gas/liquid contactor 534 positioned between the nozzles 530 and the chimney tray 536. The gas/liquid contactor 534 may provide high contact area between the gas phase of the product stream 380 and the liquid phase of the quenching fluid 510. The increased contact area between the product stream 380 and the product quenching fluid 510 can improve the heat transfer efficiency of the product stream 380 to the product quenching fluid 510 and may improve the mass transfer of catalyst fines from the product stream 380 to the product quench fluid 510. The gas/liquid contactor 534 may include packaging or trays, such as any commercially available packaging or tray suitable for gas contact. /liquid. Examples of packaging may include, but are not limited to, spheres, rings, structured packaging, other packaging, or combinations thereof.

[0059] The quench tower system 502 may include a Venturi circuit 610 that includes a Venturi contactor 612 disposed upstream of the product inlet 580 and a contactor pump 614 in fluid communication with the lower portion 690 of the quench tower 528 In some embodiments, the product stream input to the Venturi contactor 612 may be the product stream input 520 of the product processing section 500. The contactor pump 614 may be operable to pump liquid phase quenching fluids (. i.e., riser quench fluid 386, product quench fluid 510, or combinations thereof) accumulated in the lower portion 690 of the quench tower 528 to the Venturi contactor 612. The Venturi contactor 612 may be operable to contact and mix the gaseous product stream 380 with the liquid phase quench fluid drawn from the lower portion 690 of the quench tower 528. Contact and mixing of the product stream 380 with the liquid phase quench fluid in the liquid contactor 612 can transfer particulate solids from the liquid phase gas from product stream 380 to the liquid phase of the quenching liquid.

[0060] Contact and mixing of the product stream 380 with the quenching fluid from the lower portion 690 of the quenching tower 528 can also reduce the temperature of the product stream 380. In some embodiments, the quenching fluid introduced into the Venturi contactor 612 may have a temperature that is 50°C to 400°C lower than a product stream temperature 380 introduced into the Venturi contactor 612. In some embodiments, the quenching fluid temperature introduced into the Venturi contactor 612 may be lower than the temperature of the product stream 380 introduced into the Venturi contactor 612 at from 50°C to 300°C, from 50°C to 200°C, from 50°C to 150°C, from 75°C to 500°C, from 75 °C to 300°C, from 75°C to 200°C or from 75°C to 150°C. The Venturi contactor 612 may be fluidly coupled to the product inlet 580 of the quench tower 528 to introduce the mixture of the product stream 380 and the quench fluid into the quench tower 528.

[0061] With reference to FIG. 2, the quench tower 528 may include a quench fluid recycle circuit 620 that includes a quench fluid heat exchanger 622 and a quench fluid recycle pump 624. The inlet end of the quench fluid recycle circuit extinguishing fluid 620 may be fluidly coupled to the extinguishing fluid recycle outlet 586 of the extinguishing tower 528, and the outlet end of the extinguishing fluid recycle circuit 620 may be fluidly coupled to the extinguishing fluid recycle inlet 588. The extinguishing fluid recycle circuit 620 may also be in fluid communication with a product extinguishing fluid supply line 626 to supply fresh replenishing extinguishing fluid 510 to the extinguishing tower system 502. In some embodiments, the junction of the product extinguishing fluid supply line 626 with the extinguishing fluid recycle circuit 620 may effectively be the extinguishing fluid inlet 526 of the product processing section 500.

[0062] In operation, the quench fluid recycle pump 624 extracts quench fluid (i.e., a mixture of riser quench fluid 386 separated from the product stream 380 and the product quench fluid 510) from the quench fluid extinguishing fluid accumulated in the chimney tray 536 of the extinguishing tower 528. The extinguishing fluid recycle pump 624 circulates the extinguishing fluid through the extinguishing fluid heat exchanger 622, which may be operable to remove heat from the extinguishing fluid . The quenching fluid is then passed through the quenching fluid recycle inlet 588 of the quenching tower 528. The quenching fluid then passes through the nozzles 530 and into the quenching tower 528. The quenching fluid then flows downward through quench tower 528 and contacts gaseous product stream 380, which is flowing upward through quench tower 528. Quench fluid recycle circuit 620 may be operable to cool product stream 380 passing through of the extinguishing tower 528. The extinguishing fluid recycle circuit 620 may also be operable to further separate particulate solids from the product stream 380.

[0063] The quench tower system 502 may also include a product gas processing circuit 630 comprising a compressor 632, a product gas heat exchanger 634 downstream of the compressor 632, and a scavenging vessel 636 downstream of the exchanger. of heat from product stream 634. The gas processing circuit 630 may be fluidly coupled to the gas outlet 582 of the quench tower 528. The gas processing circuit 630 may be operable to separate the quench fluid from riser 386 , the product quenching fluid 510 or a combination thereof from the product stream 380 to produce the processed product stream 512 passed out of the product processing section 500. Quenching fluids (i.e., riser quenching fluids 386 , product extinguishing fluids 510, or both) may be passed from the eliminator container 636 back to the quench tower 528. In some embodiments, the gas outlet of the eliminator container 636 may be the processed product stream outlet 522 of the product processing section 500.

[0064] With reference to FIG. 2, in operation of the quench tower system 502, product stream 380 may be passed from the catalyst separation section 210 (FIG. 1), through the optional product stream heat exchanger 392 (FIG. 1), and to the Venturi contactor 612 of the Venturi circuit 610. In the Venturi contactor 612, the product stream 380 may be contacted and mixed with quenching fluid to reduce the temperature of the product stream 380 and transfer particulate solids, such as catalyst particles, from the product stream 380 to the liquid phase of the quenching fluid. The mixture of product stream 380 and quenching fluid can be passed to quenching tower 528 through product inlet 580. Gaseous product stream 380 can flow upward through quenching tower 528. Simultaneously, the quenching fluid Liquid phase quenching (i.e., including riser quenching fluid 386, product quenching fluid 510, or both) may be introduced into the quenching tower 528 through the quenching fluid recycle inlet 588 positioned in the upper portion 692 from the quenching tower 528. The nozzles 530 can distribute the product cooling fluid 510 across the cross-sectional area of the quenching tower 528. The extinguishing fluid can flow downward through the quenching tower 528. The quenching fluid liquid phase liquid may contact the gaseous product stream 380 flowing upward through the quenching tower 528. The temperature of the quenching fluid may be lower than the temperature of the product stream 380, so that heat can be transferred from the product stream. 380 for extinguishing fluid. Contact of the product stream 380 with the quenching fluid in the quenching tower 528 may further transfer particulate solids from the gas phase of the product stream 380 to the liquid phase of the quenching fluid.

[0065] After thermally contacting and/or physically contacting the product stream 380 with the product quench fluid 510, the product stream 380 may be passed through the demister 532 to remove any entrained liquid droplets or solid particles remaining in the stream. product stream 380. Product stream 380 may be passed from quench tower 528 to gas processing circuit 630. Gas processing circuit 630 may separate riser quench fluid 386, product quench fluid 510, or both from product stream 380 to produce processed product stream 512. Riser quench fluid 386 and/or product quench fluid 510 from product stream 380 may be recycled back to quench tower 528 or the extinguishing fluid recycle circuit 620 to be combined with the product extinguishing fluid 510.

[0066] Thermally and/or physically contacting the product quench fluid 510 with the product stream 380 in the quench tower 528 may produce the stream 514. The stream 514 may include at least one of the product quench fluid 510 introduced into the product quench tower 502, catalyst fines and other particulates recovered from product stream 380, riser quench fluid 386 separated from product stream 380, other compounds or combinations thereof. The current 514 may flow generally downward toward the bottom of the quench tower 528. The current 514 may collect at the bottom portion 690 of the quench tower 528 and/or may be passed out of the quench tower 528 through the liquid 584.

[0067] Although the product processing section 500 is described herein as including the quench tower system 502, it is contemplated that the product processing section 500 may alternatively include a heat transfer apparatus (not shown) and/or a mass transfer device (not shown) that can be configured in series or integrated into a unitary device. For example, the product processing section 500 may include a heat exchanger as the heat transfer apparatus for reducing the temperature of the product stream 380 and a gas/liquid contactor positioned downstream of the heat exchanger as the transfer device. of mass to remove catalyst fines from product stream 380. Examples of heat exchangers may include, but are not limited to, shell and tube heat exchangers, plate and frame heat exchangers, other heat exchangers, or combinations thereof. same. In the heat exchanger of the product processing section 500, the product quench fluid 510 may be thermally contacted with the product stream 380 via heat transfer surfaces in the heat exchanger, but may remain physically separated by the heat transfer surfaces. heat transfer. Examples of gas/fluid contactors may include, but are not limited to, particulate scrubbers or other gas/fluid contactors.

[0068] Continuous recycling of riser quench fluid 386 through the downstream reactor section 230, catalyst separation section 210, and product processing section 500 may result in the gradual accumulation of contaminants in the riser quench fluid recycled 386. Additionally, recycling the riser quench fluid 386 may result in pH changes in the riser quench fluid 386 over time. In some embodiments, water may be used for the riser quench fluid 386 and the product quench fluid 510. In these embodiments, the product processing section 500 may optionally include a separator (not shown) to remove contaminants from the water. circulated through the reaction system 102 as the riser quench fluid 386. In other embodiments, the product processing section 500 may also optionally include a system for adjusting the pH of the riser quench fluid 386 recirculated through the system. of reactor 102 and product processing section 500.

[0069] Referring now to FIG. 3, the flue gases 382 from the catalyst processing portion 300 of the reactor system 102 may also be further processed in a flue gas processing section 540. The flue gas 382 may be processed by thermally contacting the flue gas 382 with a flue gas quenching fluid 550 in the flue gas processing section 540. The flue gas quenching fluid 550 may be passed from the flue gas processing section 540 back to the reactor 202 (i.e. , the downstream reactor section 230, the upstream reactor section 250, and/or the transition section 258) as a portion of the riser quench fluid 386 to cool the intermediate product stream and the catalyst in the reactor 202.

[0070] Combustion gas 382 may be passed from the secondary separation device 320 of the catalyst processing portion 300 to a combustion gas processing section 540 positioned downstream of the secondary separation device 320. In some embodiments, the gas flue gas heat exchanger 394 disposed between the secondary separation device 320 and the gas processing section 540. The flue gas heat exchanger 394 may be operable to heat the feed stream 390 by transferring heat from the flue gas 382 to the feed stream 390. The flue gas processing section 540 may be operable to reduce the temperature of the flue gas 382. Additionally, the gas processing section combustion engine 540 may be operable to remove catalyst fines from flue gas 382 that have not been separated from flue gas 382 in secondary separation device 320. Any riser quench fluid 386 passed through catalyst processing portion 300 of the reactor system 102 with the catalyst may also be separated from the flue gas 382 in the flue gas processing section 540. In the flue gas processing section 540, a flue gas quenching fluid 550 may be introduced into the flue gas processing section 540 to reduce the temperature of flue gas 382 and/or remove entrained solids, such as catalyst fines, from flue gas 382. Flue gas quenching fluid 550 may be passed out of flue gas processing section 540 as stream 554.

[0071] Stream 554 may include flue gas quenching fluid 550. Additionally, stream 554 may include solid particles, such as catalyst fines, for example, which may be transferred from flue gas 382 to the flue fluid 550. product quench 510 and subsequently to stream 554 in flue gas processing section 540. Stream 554 may be passed back to reactor 202 as at least a portion of riser quench fluid 386. Pass stream 554 from the flue gas processing section 540 back to the reactor 202 as the riser quench fluid 386 can reduce the amount of flue gas processing fluid 554 that, in some embodiments, must be treated in downstream treatment or processing systems prior to reuse or disposal of the stream 554. Passing the stream 554 back to the reactor 202 as the riser quench fluid 386 can also improve the conversion and selectivity of the reactor system 102 by returning fines of catalyst to reactor system 102.

[0072] Still referring to FIG. 3, the flue gas processing section 540 may include a flue gas inlet 560 in fluid communication with the secondary separation device 320. In embodiments in which the flue gas heat exchanger 394 is disposed between the device of secondary separation device 320 and the flue gas processing section 540, fluid communication between the secondary separation device 320 and the flue gas inlet 560 may include fluid communication through the flue gas heat exchanger 394. The flue gas processing section 540 may also include a processed flue gas outlet 562 operable to pass a processed flue gas stream 552 out of the flue gas processing section 540. combustion 540 may also include a flue gas quenching fluid inlet 566 positioned to introduce flue gas quenching fluid 550 into the flue gas processing section 540. The flue gas processing section 540 may further include a flue gas quenching fluid outlet 564 fluidly coupled to the riser quenching fluid inlet 384 of the reactor 202 in the downstream reactor section 130, upstream reactor section 130, upstream reactor section 250 and/or transition section 258 to pass current 554 back to the downstream reactor section 230, upstream reactor section 250 and/or the transition section 258 as at least a portion of the riser quench fluid 386.

[0073] The flue gas quenching fluid 550 introduced into the flue gas processing section 540 may include steam, liquid water, liquid hydrocarbon (e.g., a quench oil, fuel oil or other hydrocarbon) or combinations thereof. The liquid hydrocarbon may include hydrocarbons having greater than or equal to 6 carbon atoms, such as from 6 carbon atoms to 25 carbon atoms or from 6 carbon atoms to 20 carbon atoms. In some embodiments, the flue gas quenching fluid 550 may include water. Alternatively, in other embodiments, the flue gas extinguishing fluid 550 may include liquid hydrocarbon, such as extinguishing oil or fuel oil, for example. In some embodiments, the flue gas quenching fluid 550 may be the same as the riser quenching fluid 386 introduced into the reactor 202. In other embodiments, the flue gas quenching fluid 550 may be the same as the riser quenching fluid 386 and the product quenching fluid 510 introduced into the product cooling tower 502.

[0074] With reference to FIG. 3, in operation of the flue gas processing section 540, the flue gas 382 may be passed from the secondary separation device 320, through the optional flue gas heat exchanger 394, and to the flue gas processing section 540. The flue gas 382 may be thermally and/or physically contacted with the flue gas quenching fluid 550 in the flue gas processing section 540. Thermally contacting the flue gas 382 with the flue gas quenching fluid combustion 550 in the flue gas processing section 540 may reduce the temperature of the flue gas 382. In some embodiments, a temperature of the processed flue gas 552 passed out of the flue gas processing section 540 may be lower than the temperature of the flue gas 382 introduced into the flue gas processing section 540 at from 50°C to 500°C, from 50°C to 400°C, from 50°C to 300°C, from 50° to 200° C, from 100°C to 500°C, from 100°C to 400°C, from 100°C to 300°C or from 100° C to 200°C.

[0075] Physically contacting the flue gas 382 with the flue gas quenching fluid 550 in the flue gas processing section 540 can remove particulate solids from the flue gas 382. In some embodiments, the processed flue gas 552 can be substantially free of particulate solids, such as catalyst fines. For example, the processed flue gas 552 passed out of the flue gas processing section 540 may have less than 0.1% by weight of particulates based on the total weight of the processed flue gas 552.

[0076] Thermally and/or physically contacting the flue gas quenching fluid 550 with the flue gas 382 in the flue gas processing section 540 may produce stream 554. Stream 554 may include the gas quenching fluid of combustion 550 introduced into the combustion gas extinguishing tower 542, catalyst fines and other particulates recovered from the combustion gas 382, other compounds and/or combinations thereof. The stream 554 may have a temperature greater than the temperature of the flue gas quenching fluid 550 introduced into the flue gas quenching tower 542, but lower than a temperature of the intermediate product stream and the catalyst in the reactor 202. The stream 554 may be passed out of the flue gas processing section 540 through the flue gas quenching fluid outlet 564.

[0077] In some embodiments, the flue gas processing section 540 may include a flue gas quenching tower system (not shown). The flue gas quench tower system may include any of the features described earlier herein in connection with the quench tower system 502 illustrated in FIG. 2 and previously described here. For example, the flue gas quench tower system may include the quench tower 528, which may include the nozzles 530, the demister 532, the chimney tray 536, and/or the gas/liquid contactor 534, as illustrated in FIG. 2. The flue gas quench tower system may also include one or more of the contact circuit 610 which includes the Venturi contactor 612 and the contactor pump 614; the quench fluid recycle circuit 620 which includes a quench fluid heat exchanger 622 and a quench fluid recycle pump 624; and/or a gas processing circuit 630 that includes the compressor 632, the gas processing heat exchanger 634, and the scavenging vessel 636. In some embodiments, the gas inlet to the Venturi contactor 612 (FIG. 2) may be the flue gas inlet 560 (FIG. 3) of the flue gas processing section 540. In some embodiments, the gas outlet of the eliminator vessel 636 (FIG. 2) of the gas processing circuit 630 (FIG. 2) may be the flue gas outlet 562 (FIG. 3) of the flue gas processing section 540. Alternatively, in other embodiments, the gas outlet of the extinguishing tower 528 (FIG. 2) may be the outlet of flue gas processing section 540 (FIG. 3) of flue gas processing section 540. In some embodiments, liquid outlet 584 (FIG. 2) of quench tower 528 (FIG. 2) may be the fluid outlet flue gas extinguishing section 564 (FIG. 3) of flue gas processing section 540.

[0078] Although described herein as having the flue gas quenching tower system, it is contemplated that the flue gas processing section 540 may alternatively include a heat transfer device (not shown) and a heat transfer device. mass (not shown) that can be configured in series or integrated into a unitary device. For example, the flue gas processing section 540 may include a heat exchanger to reduce the temperature of the flue gas 382 and a scrubber positioned downstream of the heat exchanger to remove catalyst fines from the flue gas 382. heat exchanger of the flue gas processing section 540, the flue gas quenching fluid 550 may be thermally contacted with the flue gas 382 via heat transfer surfaces in the heat exchanger, but may remain physically separate by the heat transfer surfaces.

[0079] With reference to FIG. 3, the stream 554 may be passed from the flue gas processing section 540 to the riser quench fluid inlet 384 as the riser quench fluid 386 and introduced into the reactor 202 to cool the intermediate product stream and the catalyst into reactor 202. Passing stream 554 to riser quench fluid inlet 384 to introduce stream 554 into reactor 202 as riser quench fluid 386 can, in some embodiments, reduce the amount of fluids conveyed for downstream processing and/or treatment systems, such as water treatment systems in the case of water as extinguishing fluid or downstream chemical processing systems in the case of hydrocarbon-based extinguishing fluids. Furthermore, catalyst fines transferred from flue gas 382 to stream 554 in flue gas processing section 540 may be reintroduced into reactor system 102 by passing stream 554 to reactor 202 as riser quench fluid 386 Reintroduction of catalyst fines into the reactor system 102 can improve the conversion and product selectivity of the reactor system 102.

[0080] With reference to FIG. 3, in some embodiments, the reaction system 102 may include a flue gas solids concentrator 544 and stream 554 may be passed from the flue gas processing section 540 to the flue gas solids concentrator 544. flue gas solids concentrator 544 may separate catalyst particles from stream 554 downstream of the flue gas processing section to produce catalyst fines 516 and stream 558. Stream 558 may be substantially free of catalyst particles upon passage out of the flue gas solids concentrator 544. The flue gas solids concentrator 544 may include at least one of a liquid candle filter, a bag filter, a filter press, another solids concentrator, or combinations of these. In some embodiments, the flue gas solids concentrator 544 may include at least one liquid candle filter.

[0081] As shown in FIG. 3, stream 558 may be passed from flue gas solids concentrator 544 to reactor 202 as at least a portion of riser quench fluid 386 to cool the intermediate product stream and catalyst in reactor 202. The fines of catalyst 516 may be passed from the flue gas solids concentrator 544 back to the reactor system 102. For example, the catalyst fines 516 may be passed to the catalyst processing portion 300 or to the upstream reactor section 250 of reactor system 102. In some embodiments, catalyst fines 516 may be passed to combustor 350 or section 312 of catalyst processing portion 300, where catalyst fines 516 may be processed in the catalyst processing portion 300 before being passed back to the upstream reactor section 250. As discussed previously, the catalyst fines 516 from the flue gas solids concentrator 544 may include catalyst fines having a smaller average particle size relative to the size of catalyst medium particle size in the reactor system 102. Recovering the catalyst fines 516 from the stream 554 and passing the catalyst fines 516 back to the reactor system 102 can improve the conversion and selectivity of the reactor system 102 due to to loading additional catalyst into the catalyst fines comprising catalyst fines 516.

[0082] With reference to FIG. 4, the reactor system 102 that includes both the product processing section 500 for processing the product stream 380 and the flue gas processing section 540 for processing the flue gas 382 is represented schematically. As shown in FIG. 4, riser quench fluid 386 may include stream 514 passed out of product processing section 500, stream 554 passed out of flue gas processing section 540, or both stream 514 and stream 554. In embodiments, stream 514 and stream 554 may be combined to form riser quench fluid 386 upstream of riser quench fluid inlet 384, through which riser quench fluid 386 is introduced into the reactor 202 (i.e., the downstream reactor section 230 (FIG. 1), the upstream reactor section 250 (FIG. 1), and/or the transition section 258 (FIG. 1)). Alternatively, in some embodiments, stream 514 may be passed to and through product-side solids concentrator 504 to form catalyst stream 518 and fines 516, and stream 554 may be passed to and through the solids concentrator of flue gas 544 to form stream 558 and catalyst fines 516. In these embodiments, riser quench fluid 386 may include stream 518 passed out of product side solids concentrator 504, stream 558 passed out of the flue gas solids concentrator 544, or both. Stream 518 and stream 558 may be combined to form riser quench fluid 386 upstream of riser quench fluid inlet 384.

[0083] Referring now to FIG. 5, another configuration of the reactor system 102 that includes both the product processing section 500 and the flue gas processing section 540 is represented schematically. As shown in FIG. 5, the stream 514 passed out of the product processing section 500 and the stream 554 passed out of the flue gas processing section 540 may be passed to a common solids concentrator 570 to produce the stream 572 and the flue gas fines. catalyst 516. The common solids concentrator 570 may include at least one of a liquid candle filter, a bag filter, a filter press, another solids concentrator, or combinations thereof. In some embodiments, the common solids concentrator 570 may include at least one liquid candle filter. The stream 572 may be passed from the common solids concentrator 570 to the riser quench fluid inlet 384 as at least a portion of the riser quench fluid 386 is introduced into the reactor 202 to cool the intermediate product stream and the catalyst. The catalyst fines 516 may be passed from the common solids concentrator 570 back to the reactor system 102. For example, the catalyst fines 516 may be passed back to the catalyst processing portion 300 of the reactor system 102, the upstream reactor section 250, or both. Passing both stream 514 and stream 554 to the common solids concentrator 570 can reduce the number of solids concentrators from two solids concentrators (i.e., the product side solids concentrator 504 and the flue gas solids concentrator 544 ) for just one solids concentrator (i.e., common solids concentrator 570).

[0084] According to one or more embodiments, the reaction conducted in reaction system 102 may be a dehydrogenation reaction. According to such embodiments, the feed stream may comprise one or more of ethane, propane, n-butane and i-butane. For example, if the reaction is a dehydrogenation reaction, the feed stream may comprise one or more of ethane, propane, n-butane and i-butane. In some embodiments, the feed stream may comprise at least 50% by weight ethane. In other embodiments, the feed stream may comprise at least 50% by weight propane. In still other embodiments, the feed stream may comprise at least 50% by weight n-butane. In additional embodiments, the feed stream may comprise at least 50% by weight i-butane.

[0085] In one or more embodiments, the dehydrogenation reaction may utilize gallium and/or platinum catalyst as a catalyst. In such embodiments, the catalyst may comprise a gallium and/or platinum catalyst. For example, if the reaction is a dehydrogenation reaction, then the catalyst may comprise gallium and/or platinum catalyst. As described herein, a gallium and/or platinum catalyst comprises gallium, platinum or both. The gallium and/or platinum catalyst may be carried on an alumina or silica-alumina support and may optionally comprise potassium. Such gallium and/or platinum catalysts are disclosed in US Patent 8,669,406, which is incorporated herein by reference in its entirety. However, it should be understood that other suitable catalysts can be used to carry out the dehydrogenation reaction.

[0086] The reaction may also be a cracking reaction, a dehydration reaction, a methanol to olefin reaction or another reaction. Additional details of cracking reactions, dehydration reactions, and methanol-to-olefin reactions can be found in co-pending US Provisional Patent Application 62/470,567, filed March 13, 2017, which is incorporated by reference herein in its entirety.

[0087] For the purpose of describing and defining the present invention, it is noted that the term “about” is used herein to represent the inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement or other representation . The term is also used herein to represent the degree by which a quantitative representation may vary from a stated reference without resulting in a change in the basic function of the matter in question.

[0088] It is seen that one or more of the following claims use the term “wherein” as a transitional phrase. For the purposes of defining the present invention, it is noted that this term is presented in the claims as a phrase open transition term that is used to present a recitation of a series of features of the structure and should be interpreted similarly to the more commonly used open preamble term “comprising”.

[0089] In general, “inlet holes” and “outlet holes” of any system unit of the reactor system 102 described herein refer to the openings, holes, channels, openings, clearances, or other similar mechanical characteristics in the system unit. For example, inlet ports permit materials to enter the particular system unit and exit ports permit materials to exit the particular system unit. Generally, an exit orifice or inlet will define the area of a system unit of the reactor system 102 to which a pipe, conduit, tube, hose, material conveying line or similar mechanical feature is attached, or the a portion of the system unit to which another system unit is directly attached. Although inlet holes and outlet holes may sometimes be described herein functionally in operation, they may have similar or identical physical characteristics, and their respective functions in an operating system should not be construed as limiting their physical structures.

[0090] It will be evident to those skilled in the art that various modifications and variations can be made to the present invention without departing from the spirit and scope of the invention. Since modifications, combinations, subcombinations and variations of the disclosed embodiments embodying the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed as including everything within the scope of the appended claims and their equivalents.

Claims (10)

1. Method for processing a chemical stream, the method being characterized by the fact that it comprises: - contacting a feed stream (390) with a catalyst in an upstream reactor section (250) of a reactor system (102), being that the reactor system (102) comprises the upstream reactor section (250) and a downstream reactor section (230), and contact of the feed stream (390) with the catalyst causes a reaction that forms a flow stream. intermediate product; - passing at least a portion of the intermediate product stream and catalyst from the upstream reactor section (250) to the downstream reactor section (230); - introducing a riser quench fluid (386) into the downstream reactor section (230), into the upstream reactor section (250), or into a transition section (258) between the downstream reactor section (230 ) and the upstream reactor section (250) and in contact with at least a portion of the intermediate product stream and the catalyst in the downstream reactor section (230), the upstream reactor section (250), or the transition section (258) to slow or stop the reaction of the intermediate product stream with the catalyst to form a product stream (380), the riser quench fluid (386) having a temperature lower than a temperature of the intermediate product; - separating at least a portion of the catalyst from the product stream (380) in a downstream catalyst separation section (210) of the downstream reactor section (230); - passing at least a portion of the product stream (380) and the riser extinguishing fluid (386) to a product processing section (500); - introducing a product quenching fluid (510) to the product processing section (500) to provide cooling of at least a portion of the product stream (380) in the product processing section (500); and - separating at least a portion of the riser extinguishing fluid (386) from the product stream (380) in the product processing section (500), wherein the riser extinguishing fluid (386) introduced into the processing section (500) The downstream reactor (230), the upstream reactor section (250), or the transition section (258) comprises at least a portion of the riser quench fluid (386) separated from the product stream (380). 2. Method according to claim 1, characterized in that the product processing section (500) comprises an extinguishing tower (528). 3. Method according to any one of claims 1 or 2, characterized in that the riser extinguishing fluid (386) comprises water, hydrocarbon, or both. 4. Method according to any one of claims 1 to 3, characterized by the fact that it further comprises removing catalyst fines (516) from the product stream (380) in the product processing section (500) and passing the catalyst fines (516) back to the reactor system (102). 5. Method according to any one of claims 1 to 4, characterized by the fact that it further comprises passing at least a portion of the riser extinguishing fluid (386) separated from the product stream (380) through a heat concentrator. solids (544) to remove catalyst fines (516) from at least a portion of the riser quench fluid (386) and pass the catalyst fines (516) back to the reactor system (102). 6. Method for processing a chemical stream, said method being characterized by the fact that it comprises: - contacting a feed stream (390) with a catalyst in an upstream reactor section (250) of a reactor system (102), in that the reactor system (102) comprises the upstream reactor section (250) and a downstream reactor section (230), and contact of the feed stream (390) with the catalyst causes a reaction that forms a flow stream. intermediate product; - passing at least a portion of the intermediate product stream and catalyst from the upstream reactor section (250) to the downstream reactor section (230); - introducing a riser quench fluid (386) into the downstream reactor section (230), into the upstream reactor section (250), or into a transition section (258) between the downstream reactor section (230 ) and the upstream reactor system (250) and in contact with at least a portion of the intermediate product stream and the catalyst in the downstream reactor section (230), the upstream reactor section (250), or the transition section (258) to slow or stop the reaction of the intermediate product stream with the catalyst to form a product stream (380), the riser quench fluid (386) having a temperature lower than a temperature of the intermediate product; - separating at least a portion of the catalyst from the product stream (380) in a downstream catalyst separation section (210) of the downstream reactor section (230); - passing at least a portion of the catalyst to a catalyst processing portion (300) of the reactor system (102); - processing at least a portion of the catalyst in the catalyst processing portion (300), wherein processing the catalyst forms a combustion gas and a processed catalyst; - passing at least a portion of the processed catalyst from the catalyst processing portion (300) back to the upstream reactor section (250); - passing the flue gas to a flue gas processing section (540); - thermally contacting the flue gas with a flue gas quenching fluid (550) in the flue gas processing section (540) to cool the flue gas in the flue gas processing section (540) and separate fines combustion gas catalyst (516); and - passing at least a portion of the flue gas quenching fluid (550) to the downstream reactor section (230), the upstream reactor section (250), or the transition section (258), wherein the riser quenching fluid (386) comprises at least a portion of the flue gas quenching fluid (550). 7. Method according to claim 6, characterized in that the flue gas processing section (540) comprises a quenching tower (542) and the flue gas quenching fluid (550) comprises water, hydrocarbon or both. 8. Method according to any one of claims 6 or 7, characterized in that it further comprises: - passing at least a portion of the combustion gas extinguishing fluid (550) to a solids concentrator (544), being that passing the flue gas quenching fluid (550) through the solids concentrator (544) removes catalyst fines (516) from the flue gas quenching fluid (550); and - passing the catalyst fines (516) back to the reactor system (102). 9. System for processing a chemical stream, the system being characterized by the fact that it comprises: - a reactor portion of a reactor system (102), the reactor portion comprising: - an upstream reactor section (250); - a downstream reactor section (230); - a transition section (258) between the upstream reactor section (250) and the downstream reactor section (230); - a riser quench fluid inlet (384) positioned to introduce a riser quench fluid (386) into the downstream reactor section (230), the upstream reactor section (250), or the transition (258); and - a separation device (220) operable to separate a catalyst from a product stream (380); - a catalyst processing portion (300) comprising: - a combustor (350) configured to receive catalyst from the separation device (220); and - a separation section downstream (210) of the combustor (350) and configured to separate the catalyst from a combustion gas; - a product processing section (500) comprising a product stream inlet in fluid communication with the separation device (220), a quenching fluid inlet (526) operable to introduce a product quenching fluid (510 ) in the product processing section (500), a processed product stream outlet (522) operable to pass a processed product stream (512) out of the product processing section (500), and a product processing fluid outlet extinguishing (524) fluidly coupled to the rising tube extinguishing fluid inlet (384); wherein the product processing section (500) is operable to: - reduce a temperature of the product stream (380); - separating at least a portion of the riser extinguishing fluid (386) from the product stream (380); and - passing at least a portion of the riser extinguishing fluid (386) out of the extinguishing fluid outlet (524), wherein the riser extinguishing fluid (386) comprises the at least a portion of the extinguishing fluid (386) riser extinguisher (386) separate from the product stream (380) in the product processing section (500). 10. System, according to claim 9, characterized by the fact that it further comprises: - a combustion gas processing section (540) comprising a combustion gas inlet (560) in fluid communication with the combustion processing portion reactor catalyst (300), a flue gas quenching fluid inlet (566) operable to introduce a flue gas quenching fluid (550) into the flue gas processing section (540), a gas outlet flue gas processing section (562) operable to pass a processed flue gas stream (552) out of the flue gas processing section (540), and a flue gas quenching fluid outlet (524) fluidly coupled to the riser extinguishing fluid inlet (384); and wherein the flue gas processing section (540) is operable to: -reduce a flue gas temperature; and - passing at least a portion of the flue gas quenching fluid (550) out of the flue gas processing section (540), the riser quenching fluid (386) comprising at least a portion of flue gas quenching fluid (550) passed out of the flue gas processing section (540).